Chili powder is generally not spicy (unless, of course, it's labeled as such), so that should be fine. If the recipe calls for cayenne, chipotles, or red pepper flakes, consider reducing those. I would probably just make a recipe as you like it and let him try it.

I just make a very basic chilli because we don't like spicy food. I can post the recipe I used a couple of days ago later. My kids don't eat it though. But, it's because they are picky and don't tend to like meat dishes. I also haven't made it in a VERY long time. So, it was new to them, which rarely goes over very well. LOL. However, one of my 2 year olds really liked it.

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Heather SAHM to 6 who are 7 and under, including 2 sets of twins and our last little miracle, a surviving identical twin, born Oct 2012!

ditto everyone else. my 3 yr old LOVES spicy food. i don't generally do anything different for him. we just had chili last week and he inhaled it. sometimes, if we're having a particularly spicy dish, i do cut down a bit on the red/cayenne pepper or whatever spice is giving it the "heat" but usually it's not a problem. i would just go with your normal recipe and cut down whatever is giving it the spiciness (cayenne pepper, hot red pepper flakes, chile powder (not to be confused with chili powder which is a spice mix and not generally very hot)